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Development of Novel Tool Center Point Velocity Planning Algorithm for Five Axis Machine Tool
Shih-Kai Wu,Meng-Shiun Tsai,Ming-Tzong Lin,Hong-Wei Huang 한국정밀공학회 2018 International Journal of Precision Engineering and Vol.19 No.8
In this paper, a tool center point (TCP) feedrate scheduling algorithm for 5-axis machine tool is developed to generate the axes interpolation commands. The proposed algorithm considers not only the constraints of TCP velocity, acceleration and jerk, but also the velocity differences of each axes at the junction of each block. First, the proposed method determines the maximum speed for each block segment at the TCP coordinate based on the computed length. Then the kinematics of the five axis machine tool is employed to derive the five-axis corner velocity difference (FCVD) formulation. The FCVD utilizes the axis velocity difference at the junction of blocks as the designed variable. As the starting and end velocities of each block are determined, the S-shape acceleration/ deceleration (Acc/Dec) method is adopted to generate both smooth TCP and rotary axis profile based on the given interpolation parameters. The servo dynamics of the five axis machine tool are utilized to evaluate the performances of the FCVD. Simulation results demonstrate that the FCVD can achieve better contour accuracy with less machining time as compared to the five-axis feedrate regulation formulation (FFRF) algorithm. Furthermore, the FCVD are compared with Heidenhain CNC controller and the results show that the FCVD has similar behaviors as the Heidenhain controller, but it can achieve less machining time.
Analysis of Tool Wear by Using a Cutting Bending Moment Model for Milling Processes
Hsiang-Chun Tseng,Meng-Shiun Tsai,Bu-Ci Yeh,Kuan-Ming Li 한국정밀공학회 2022 International Journal of Precision Engineering and Vol.23 No.8
In this study, we developed a bending moment model that considers the cutting forces acting on a sensory tool holder along the rotational direction. The polar plot of the bending moment during cutting can be used to investigate the cutting behavior. Cutting processes with different cutting depths and widths result in different polar plots, as verified experimentally. To evaluate the effect of tool wear on the polar plot, the bending moment equations were modified to incorporate the developed tool wear model. The simulation results indicated that tool wear can increase the size of the polar plot and vary the angle of the plot. By examining the change of this angle, one can determine the level of tool wear. The experimental results of this study indicated that the derived equation can predict the tool wear behavior with an average accuracy of 84%. Thus, the proposed integrated model enables the accurate prediction of tool wear. Consequently, the polar plot can feasibly be used to detect the level of tool wear.